Box construction



Nov. 30, 1954 P. WAHL 2595728 BOX CONSTRUCTION Filed Nov. 8 1951 INVEN7'O'R PAUL L. WAHL MWm This invention relates to the construction of boxes and receptacles and more particularly to a generally rectilinear box construction formed from a sheet blank so as to have curvilinear corners at each intersection of the walls thereof.

In the manufacture of boxes cf the type described it has been cornmon practice to form the box by a drawing process wherein the box is fabricated from a sheet blank by placing the blank in a press and performing one or more drawing operations thereon. Although the box thus formed may have the desired rounded corners at the juncture of the walls thereof, the process of manufacture is subject to certain disadvantages. For example, the dies utilized in forming the box can be used in forrning a box cf only one sizes, that is, the same dies cannot be used when it is desired to vary the overall dimensions of the box. In addition, the cost of the dies is relatively high and a great deal of tirne is involved in changing one set of dies for another within a press in order to condition the press for production of boxes of a different size. T he cost of the box inanufactured by such process is also increased in that a relatively heavy sheet blank must be used in order to withstand the drawing process and in addition only certain types of relatively high quality metals can be utilized in a drawing process.

It is an object of the present invention toprovide an improved process for forming a box from a sheet blank,

said process to involve stamping 01 cutting theblanks so that the same may be formed into a box having rounded corners without involving the use of drawing presses whereby the box may be most econornically formed from lightweight and inexpensive sheet material.

A further object of the present invention is to provide means for forming a box of the type described from a sheet blank wherein only relatively inexpensive tools need be utilized and wherein said tools can be used in the fabrication of the corners of boxes of difierent sizes.

Other objects Will be in part obvious and in part pointed out more in detail hereinafter.

The invention accordingly consists in the features of construction, combination of elements and arrangement of parts which will be exemplified in the construction hereafter set forth and the scope of the application of which will be indicated in the appended claims.

In the drawings:

Fig. 1 is a fragmentary view of a blank utilized in constructing a box according to the present invention and showing particularly the configuration of a section of the blank utilized to form a rounded corner joining adjacent side walls;

Fig. 2 illustrates the details of the corner construction and an intermediate step in the formation of the box;

Fig. 3 is a view similar to Fig 2 which shows the completed corner referred to above; and

Fig. 4 is a view similar to Fig. 3 showing a modified corner construction.

The box of the present invention is to be formed from a blank of sheet material as, for example, a thin sheet metal blank 10. In Fig. 1 one corner portion of the blank is shown, and in the construction of a polygonal box, the number of such corner sections corresponds to the number of sides. For example, in the construction of a feursided box, the blank Will be provided with four corner sections similar to the sections shown in Fig. 1.

The blank per se comprises a bottom portion 11 having integrally forrned thereon peripheral portions 12 and 13 which in the process of forming the box will comprise United States Patent O adjacent side walls thereof. One side wall portion 12 has one end edge 14 which is substantially normal to the edge 15 on the adjacent end of the side Wall portion 13.

If the box were to be formed With sharp corners, the side wall portions 12 and 13 could be bent relative to the bottom portion 11 along the dash lines 16 to a substantially normal position relative to the bottom 11 whereby the side walls would join in a sharp corner along the edges 14 and 15, said corner also being normal to the bottom 11. However, in accordance with the present invention the blank is to be formed into a box having rounded corners and the side walls 12 and 13 are curved as at 17 adjacent the dash lines 16. The body portion of the side walls in the present construction are substantially normal to the bottom 11 and due to the curvature 17 the edges 14 and 15 Will be in spaced relation to each other when the side walls assurne the aforernentioned normal position.

The space between the adjacent edges 14 and 15 is closed in the present construction by providing the side wall 13 with an extension adjacent the edge 15. The extension 20 is arranged to be convexly outwardly curved as indicated at 21 along an axis parallel to the edge 15 whereby the leading edge 22 on the extension Will abut against the edge 14 on the side 12 to provide a rounded vertical corner as shown in Fig. 3.

In order to join the rounded vertical corners between adjacent side walls with the rounded corners between the side walls and the bottom of the box, the extension 20 is notched as at 24 to define a generally triangular downwardly depending tongue 25 which is formed into a convexly outWardly curved shell, the peripheral edges of which join the side Wall edges 14 and 15 to provide a parti-spherical surface at the juncture of the horizontal corners 17 and vertical corner 21. In forming the tongue 25 into a parti-spherical shell, the notches 24 are substantially closed to provide a substantially imperforate curvilinear corner construction joining adjacent side walls and the bottom Wall of the box. The a'butting edges of the elements comprising the aforedescribed corner construction are to be secured together as by soldering,'welding, or the like.

It should be understood that the aforedescribed corner construction is to be utilized in forming each of the corners of the box and it should also be understood that the blank 10 can be cut and formed in the aforedescribed manner by an operator utilizing the most simple of hand tools. However, to expedite the process, the corner portions of the blank can be stamped in a conventional punch press into the form shown in Fig. l, by placing only the corner portions o:f the blank into the press. Thereafter conventional metal forming machinery and tools can be used to forrn the rounded corners in the stamped blank. Obviously, the stamping press and the tools utilized in forming the box in the manner described can be utilized in the construction of the boxes of varying sizes, thereby making it unnecessary to change dies when it is desired to change frorn the manufacture of one size box to a box cf another size.

The above described means and method for forming a box relates to straight-sided open-topped boxes, but in addition, the box cn be provided wit'h an internally directed ledge or shoulder 30 to accommodate a cover which may be formed similarly to the box. In suiting the blank 10 for the construction of boxes having such a ledge the side walls 12 and 13 are ofifset by bending the same along the dash and dot lines 3110 the configuration shown in Figs. 2 and 3. In such constructions the side Wall extensions 20 are notched as at 32 adjacent their upper edges to define a plurality (three shown) of tooth-like ears 33 which join each other in edge-abutting relationship when the extension 20 is rounded or curved as at 21. rounded corners symmetrical to the vertical corners of the box.

The upper edge of the box may be provided With a reinforced rim by folding the peripheral margin of the side walls inwardly and downwardly along dash lines 35 to the position shown in Fig. 2. The folded upper edges of the adjacent side walls may be conveniently joined by providing one of the side walls with an extension 36 ad- Thus, the ledge 30 is also provided Witll manner.

the edge, as shown in Fig. 2, may be folded upon itself as indicated by reference numeral 37 to provide a hook for receiving an ear 38 defined in the upper corner of the adjacent side, wall as by cutting thesame a t 39.

The ear 38 may b.e disposed between the extension 36 and the folded section 37 thereof to secure the adjacent side Walls in edge-abutting relationship. The rovision of the aforedescribed s ecuring means facilitates assembly of the box frorn the blank by holding the. side alls in said edge-abutting relation until the solder or other securing and sealing means is applied to the corner.

In Fig. 4 there is illustrated a modification of the coustruction ofthe corners for the aforedescribed box Wherein the extension 20 is provided with an extending leaf 40 adapted to oyerlie the outer surface of the adjacent side wall when the comer is formed in the aforedescribed The leaf 40 is then secured to said adjacent side Wall by spot welding or the like a s indicate d at 41. In such modified construction, however, the seams forrned by the abutting edges of the adjacent side Walls are filled With solder or otherwise sealed as, for example, by a butt welding process.

If desired, 12116}COII161 construction shown in Figs. 1 to 3 may be reinforced by various means as for example a curved plate (not shown) afi1xed either internally or externally to the adjacent side Walls as by spot welding or the like. However, the aforedescribed corner construction is remarkably strong and in most cases reinforcing means Will be unnecessary.

I1: will be seen that boxes can be formed according to the present invention from very thin sheet blanks since there is no drawing process involved such as will change the cross-sectional structure of the blank utilized. It Will also be seen that the box may be formed by following the simple steps ofthe aforedescribedmethod and without the use of expensive machinery or apparatus.

As many changes could be made in the above construc-- drawings shall be interpreted as illustrative and not in a,

limiting sense.

It is also to be understood that the language used in the fol lowing claims is intended to cover all of the generic and specific features of the invention herein described 7 and all statements of the scope of the;inventionwhich,

as a matter of language, might be said to fall therebetween.

I claim as my invention:

l. A blank for forming an open top box comprising a polygonal sheet having a body portion and extending side portions adapted tobe folded upwardly With respect to said body portion to define ronnded horizontal edges therealong, each of said side portions having a lateral extension for forming a rounded vertical. edge between said side portion and an adjacent side portion and for defining a parti-spherical corner between said vertical edge and the adjacent horizontal edges, said extension comprising a generally rectangular portion adapted to be formed as the rounded vertical edge and a generally triangular tongue depending from the rectangular ortion and defined by aligned notches extending toward each other from opposite sides ofi said extension between said rectangular portionand; said triangular tonguewherebythe said tongue may be formed in parti -spherical shape so that the apex thereof; will engage the body portion of the blank and so that the side edges thereof Will ehgage the adjac ent rounded horizontal edges.

2. A corner, structure fo1 an open top box having rounded horizontal and vertical edgescomprising a lateral extension in one Wall of the box haying a rec tangular portion formed'to define a rounded vertical edge engaging the adjacent wall of the box, andsaid extension also having a generallytriangulartongue depending from said rectang ular portion and defined by alignenotches extending toward each other frox n opposite sides of said extension between said rectangulan p0rtionand said triangul1r tongue, said tonguev b.eing formed in. partispherical shape with its apex engaging the bottonr of the box and with its side edg es engaging the adjacer1t munded horizontal edges.

References Cited in the file of this patent UNLTED STATES PATENTS Number Name Dato 537,119 Levcy Apr. 9, 1895 1725903 Duv.all Aug. 27, 1929 1929742 Hedlnd Oct; 10, 1933 2093926 Pratt Sept. 21, 1937 2194722 Roberts j Mar. 26 1940 

